Ingersoll-Rand ES 115V AC Series Maintenance Information

Brand: Ingersoll-Rand

Model: ES 115V AC Series

Type: Maintenance Information

45527785

Edition 1

July 2008

Save These Instructions

Electric Screwdrivers

ES 115V AC Series

Maintenance Information

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WARNING

Always wear eye protection when operating or performing maintenance on this tool.

Always turn o the air supply and disconnect the air supply hose before installing, removing or adjusting any accessory on this tool or

before performing any maintenance on this tool.

Note: (When reading the instructions, refer to exploded diagrams in parts Information Manuals when applicable (see under Related Documentation

for form numbers).

Disassembly

Using a No. 2 tip Phillips head screwdriver on the Housing

Screws (1B) and a No. 1 Phillips head screwdriver on the Coupling

Screws (36B or 3SB), remove the two Coupling Screws and the

three Housing Screws.

NOTICE

The screw threads are coated with Threadlocker 222®*. It may be

necessary to rapidly tap the end of the screwdriver handle with a

hammer while backing the Screws out of the Housing.

Coupling Screw

Housing Screw

(Dwg. TPD1029)

2. Remove the Coupling (36A or 3SA) by pulling it o the front end

of the Electric Screwdriver.

Coupling

(Dwg. TPD1030)

3. Carefully separate the two halves of the Housing (1A) by using a

thin blade screwdriver to pry them apart.

* Registered trademark of Loctite Corporation.

(Dwg. TPD1031)

4. With the assembled motor elevated slightly from the Housing,

pull the Gear Case Assembly (21 or 22) away from the assembled

motor.

Pilot Rod “H”

Gear Case Assembly

(Dwg. TPD1032)

5. Remove the Pilot Rod “H” (27 or 28) from the Gear Case Assembly.

6. Using a thin blade screwdriver, spiral the Retaining Ring (39C or

41C) out of the front of the Clutch Housing Assembly (34 or 36).

Remove the Bit Sleeve (39A or 41A), Bit Spring (39B or 41B) and

the Bit Retaining Balls (40 or 42). Loosen the Spring Adjusting

Ring (37 or 39) until it is just nger tight.

Retaining Ring

Ball Retaining Ball

Spring Adjusting Ring

Clutch Housing Assembly

Bit Sleeve

Bit Spring

(Dwg. TPD1033)

45527785_ed1 3

7. Fit the two notches at the rear of the Gear Case Assembly (21 or

22) into an assembly xture and using an open end wrench on

the ats on the Clutch Housing Assembly (34 or 36), unscrew and

remove the Clutch Housing Assembly.

NOTICE

This is a left-hand thread.

Clutch Housing Assembly

Gear Case Assembly

Gear Case Notch

(Dwg. TPD1034)

ES6OT Clutch Housing Fixture

Steel Tubing 1 1/2” LG. x 1 35/64” O.D x 1 5/16” I.D

Steel 1 7/8” LG. x 35/64” x 3/32”

Weld Outside Only

Steel 2” SQ. x 1/2” Thick

.551

.541

(Dwg. TPD1053)

Removing the Clutch Housing from the Gear Case

Gear Case Assembly

3/16” Flat Stock

Flats on Clutch

Housing Assembly

(Dwg. TPD1056)

8. Remove the Taper Ring Assembly (29 or 30), Cam Guide (28B

or 29A) and Cam Guide Balls (28C or 29B) from the Gear Case

Assembly. For Model ES5OP, ES1OOP or ES1OOT, remove the

Cam (26A or 27A), Cam Pins (26B or 27B) (2 for model ES80P and 4

for model ES1OOP or ES100T) and the Cam Washer (26C or 27C).

For Model ES90P or ES90T, remove the Cam (25 or 27). Remove

the Spindle Assembly (24 or 25) and the two Spindle

Washers (24C or 25C) from the Gear Case Assembly.

For all other models, remove the Cam (25 or 27). Remove the

Spindle Assembly (24 or 25), Gear Head Sun Gear (23 or 24) and

Gear Head Assembly (22 or 23) from the Gear Case Assembly. Do not

attempt removal of the ring gear inside the Gear Case. It is a press t

into the Gear Case.

Taper Ring Assembly

Cam Guide Ball

Cam

Cam Guide

Ring Gear

Gear Case

Gear Head Sun Gear

Spindle Assembly

Gear Head Assembly

(Dwg. TPD1035)

9. Slide the Bit Holder Assembly, Clutch Spring (30 or 31) and Spring

Plate (33 or 35) out of the Clutch Housing.

NOTICE

Trigger models have a Holder Bearing Assembly. Remove the

Assembly from the Clutch Housing.

Clutch Housing

Clutch Spring

Spring Plate

Bit Holder Assembly

(Dwg. TPD1036)

10. Unscrew and remove the Cover (38 or 40). Unscrew and remove

the Spring Adjusting Ring (37 or 39) and pull the three Clutch

Adjusting Pins (35 or 37) out of the Clutch Housing.

Cover

Spring Adjustment Ring

Clutch Adjustment Pins

Clutch Housing

(Dwg. TPD1037)

11. Pull the Pilot Rod “H” (27 or 28) out of the Bit Holder and using

miniature, internal snap ring pliers, remove the Stop Ring (32E or

33E) from the Bit Holder (31A or 32A).

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NOTICE

Spread the Ring only enough to remove it from the Bit Holder.

Excessive expansion may damage the Ring.

12. Remove the Washer (32D or 33D), Slide Ring Spring (32C or 33C),

Slide Ring Washer (32B or 33B) and Slide Ring (32A or 33A) from

the Bit Holder.

Pilot Rod "H"

Retaining Ring

Washer

Slide Ring Spring

Slide Ring

Pilot Cam Ball

Pilot Retaining Ring

Slide Ring Washer

Pilot Cam Ball

Bit Holder

Pilot

Pilot Ball

(Dwg. TPD1038)

13. When the Slide Ring is removed, the two Pilot Cam Balls (32 or

33) will come out of the Bit Holder. Removing the Balls allows the

Pilot (31B or 32B), Pilot Ball (31C or 32C) and Pilot Retaining Ring

(31D or 32D) to be removed from the end of the Bit Holder.

NOTICE

The Pilot Ball must be clean to be removed from the Pilot.

However, only remove the Pilot Ball and Pilot Retaining Ring if

it is necessary.

14. Remove the Front End Plate Washer (if the tool has one), the Fan

Sun Gear (19 or 20) and the Armature Fan (18 or 19) from the

front of the motor.

NOTICE

The Front End Plate Washer consists of one or more thin, semi-

transparent plastic pieces. Pull the Pilot Rod “G” (20 or 21) out of

the Fan Sun Gear.

WARNING

Do not lose, substitute or damage Pilot Rod “G”. It is a critical

component of the tool’s electrical insulation system and any

substitution, omission or damage could cause a shock.

Pilot Rod “G”

Armature Fan

Assembled Motor

Front End Plate Washer

Fan Sun Gear

(Dwg. TPD1039)

15. If additional disassembly is required, unsolder the Capacitors

(15A or 16A) and (16 or 17) from the Control Base (7A or 8) and

from the end of the Upper Motor Assembly Spring (15B or 16B).

Rear End Plate

Upper Motor Assembly Spring

Brush Cap

Brush Assembly

(Dwg. TPD1040-2)

16. Unscrew and remove the two Brush Caps (15 or 16) and pull the

two Brush Assemblies (14A or 15A) out of the Rear End Plate (14

or 15). Mark the Brushes so they can be reinstalled exactly as they

were removed unless they are replaced.

17. Using a thin blade screwdriver, remove the Motor Assembly

Springs (15B or 16B) by inserting the screwdriver between the

Spring and Rear End Plate and prying upward.

Assembly Spring

Screwdriver

(Dwg. TPD1041)

18. Remove the Rear End Plate (14 or 15) and the Front End Plate

(15G or 16G) from the Yoke Assembly (15E or 16E) and Armature

Assembly (15D or 16D). If Insulators (16 or 17) and Washers (16A

or 17A) are removed, replace them with new ones.

CAUTION

Do not separate the Armature Assembly from the Yoke Assembly.

The magnet in the Yoke will become slightly demagnetized and

adversely aect motor performance.

Front End Plate

Yoke Assembly

Rear End Plate

Armature Assembly

(Dwg. TPD1042)

45527785_ed1 5

Assembly

To assemble these tools, reverse the disassembly procedure.

There are certain assembly and lubrication instructions which are

important for optimum performance and they are as follows:

Keep the commutator surface of the armature free from all

contaminants.

Use good quality, properly sized snap ring pliers when installing

the Stop Ring (32E or 33E) on the Bit Holder (31A or 32A) and

do not expand the Stop Ring more than required to install it on

the Holder. Excessive expansion may cause the Ring to deform

and fail.

To assemble the Clutch Housing Assembly to the Gear Case

Assembly, proceed as follows:

Apply 0.3 cc of Ingersoll Rand No. 67 Grease to the Spindle

Assembly (24 or 25).

Insert the Cam (25, 26A or 27), small end rst, into the Gear

Case (21 or 22).

Inject a small amount of grease into the holes for the Cam

Guide Balls (28C or 29B) and insert a Cam Guide Ball into each

hole.

For model ES5OP, insert a Cam Pin (26B or 27B) between each

of the two Cam Guide Balls and hold each in position with a

small amount of grease.

For Model ES1OOP or ES1OOT, insert a Cam Pin between

each of the four Cam Guide Balls and hold each in position

with a small amount of grease.

Being careful not to dislodge the Cam Guide Balls or Cam

Guide Pins, thread the Gear Case onto the Clutch Housing

about two threads.

NOTICE

This is a left-hand thread.

e. At the middle of the Clutch Housing thread, apply Loctite

Threadlocker 242, or equivalent, to approximately three

threads.

Apply Bonding Agent Here

(Dwg. TPD1044)

f. Carefully thread the Clutch Housing into the Gear Case until

contact is made with the Cam. When contact is made, unscrew

the Clutch Housing two full thread revolutions.

g. Insert a 114” tee wrench or hex wrench into the end of the Bit

Holder (31A or 32A). While pushing the Bit Holder inward with

the wrench, rotate the Gear Case until the jaws of the Cam

Guide (28B or 29A) engage the Cam. The wrench will move

inward noticeably when engagement occurs.

h. While maintaining engagement with the wrench, hand

tighten the Gear Case as much as possible.

i. With the assembly xture held in vise jaws, position the

notches in the Gear Case onto the xture and, using a torque

wrench, tighten the Clutch Housing to 21 ft-lb (28.5 Nm)

torque. Refer to Drawing TPD1053 on Page 3.

NOTICE

Recalibrate the torque wrench every six months.

orque Wrench

Assembly Fixture

(Dwg. TPD1045)

4. The brake switch must be timed to actuate when the clutch cams

over. To adjust the timing, loosen the Adjusting Screw Nut (13B or

14B) and turn the Adjusting Screw (13A or 14A) in or out until the

microswitch (12A or 13A) is actuated at the same time the clutch

cams over or slightly before it cams over, If the motor lug before

the brake switch actuates, shorten the Adjusting Screw.

Clutch Shut-o/Brake Switch

Adjustment for Shuto



(Dwg. TPD1046)

Lubrication

Whenever an Electric Screwdriver is disassembled for maintenance

or repair, lubricate the following components in the recommended

manner with Ingersoll Rand No. 67 Grease.

Inject a tiny amount of grease into the hole in the Pilot (31B or

32B) for the Pilot Ball (31C or 32C).

Wipe a lm of grease on the tapered inner surface of the Slide

Ring (32A or 33A) and the Taper Ring Assembly (29 or 30).

Apply a moderate amount of grease to the outer surfaces of the

Cam (25, 26A or 27), the Cam Guide (28B or 29A) and the Cam

Guide Balls (28C or 29B).

Wipe a thin coat of grease on each of the Spindle Gears (24A or

25A).

CAUTION

Do not pack the gearing with grease. Excess grease may be

pulled into the motor by the Armature Fan (18 or 19).

WARNING

Pilot Rod “G” (20 or 21) must be totally free of grease. Grease on

this Rod could cause electric shock.

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Troubleshooting Guide

Trouble Probable Cause Solution

Screwdriver fails to

rotate (forward or

reverse).

Does the microswitch “click”

when the bit is pushed rearward

on push to start models or when

the trigger is depressed on

trigger models?

Starting microswitch is defective; replace the microswitch.

Pilot Rod “H” is binding; clear obstruction or replace Rod.

Pilot Rod “G” or Pilot Rod “ H is defective; repair or replace Rod.

Bit Holder is binding; clear the obstruction.

Incorrect Pilot Rod; Check each rod length and place each length in its proper

position.

Incorrect assembly of Clutch; check clutch parts and balls for proper assembly.

Stop Ring out of position; install the Stop Ring correctly.

With tool unplugged, can bit be

rotated manually?

Defective planetary gearing; replace the defective parts.

Defective Clutch; replace the defective parts.

Defective Motor; replace the Motor.

Are the Brush Assemblies in

good condition?

Brushes are worn or cracked; replace the Brush Assemblies.

Commutator worn; replace the motor.

Remove the Coupling, separate

the Housing halves and plug the

tool into an electrical receptacle.

Using a voltmeter, make the

following determinations:

WARNING

This procedure has the potential for severe shock hazard and should be

performed by qualied personnel.

Is there voltage to the Motor?

Motor is defective; replace the Motor.

Brushes are defective; replace the Brush Assemblies.

Is there voltage to the Reverse

Switch?

Coil is defective; replace the Coil.

Wiring is defective; replace any broken wires and resolder any defective solder

connections.

Is there voltage to the Reverse

Switch?

Reverse Switch is defective: replace the Reverse Switch.

Solder connections are defective; resolder any defective solder connections.

Is there voltage out of the Power

Switch?

Power Cord is defective; replace the Power Cord.

Solder connections defective; resolder any defective solder connections.

Is there voltage to the Controller?

Controller is defective; replace the Controller.

Solder connections are defective; resolder any defective solder connections.

Replace the On/O Switch.

Screwdriver operates

in one direction but

will not operate in the

opposite direction.

Are the wire leads in good

condition?

Solder connections are defective; resolder any defective solder connections.

Does the “Forward-Reverse”

Switch function properly?

Defective “Forward-Reverse” Switch; replace the Switch.

Bit does not rotate

but motor hums.

When the gears are removed, will

the motor rotate?

Armature is in contact with the magnets; replace the motor.

Foreign material in the motor; clean the motor.

Is the planetary gearing smooth

when the bit is rotated by hand?

Bearing has failed; replace the bearing.

Gears are worn or damaged; replace any defective gearing.

Damaged Gear head Seat or Seat Retainer; replace damaged component.

Clutch Assembly is worn; replace damaged or worn parts.

Motor runs but the Bit fails to rotate.

Armature Fan is defective; replace the Armature Fan.

Gears are worn or damaged; replace any defective gearing.

45527785_ed1 7

Trouble Probable Cause Solution

Shut-o Brake

malfunctions more

than one index of

the Clutch.

Does Bit speed exceed rated speed by

more than 100 rpm?

Motor magnet is demagnetized; replace the motor.

Is Shut-o Brake microswitch functioning?

(Does it click when button is depressed an

does it test correctly with an ohmmeter?)

Defective microswitch; replace the microswitch.

Is the Shut-o Brake Switch in the “ON”

position when the Bit Holder is fully

depressed?

Pilot Rods “H”, “G” and “F” are worn; check Rod length. Replace if necessary.

Pilot Rod “D” out of adjustment; readjust with Adjusting Screw.

Loose Clutch Housing Assembly; tighten the Clutch Housing Assembly.

With one lead disconnected, does Resistor

(R10) show approximately 20 ohms on an

ohmmeter?

Resister is defective; replace the Resistor.

Controller package is defective; replace the Controller.

Cam is worn and not providing adequate lift; replace the Cam.

Bit Holder cannot be depressed

Bit Holder is defective; repair or replace the Bit Holder.

Retaining Ring on Bit Holder has been lost or is out of position.

Tool makes

abnormal sounds

when the motor is

running.

Is there looseness at the assembled

points.

Screws are loose; tighten all Screws

Clutch Housing is loose; tighten Clutch Housing to proper torque.

After removing the gear train does the

motor sound normal when running?

Armature is in contact with the magnet; replace the motor.

Foreign material has gotten into the motor; clean or replace the motor.

Ball bearings are defective; replace the Motor.

Armature is defective; replace the Motor.

Is the gear train properly lubricated?

No grease on the gear train; apply a thin lm of the recommended grease.

Spindle Bearing has failed; replace the Spindle Assembly.

Gears are worn or dirty; clean or replace the gears.

Tool generates

abnormal heat

when operating.

After removing the gear train, does the

tool cool down and motor run normally?

Motor is defective; replace the motor.

Planetary gears and the Clutch require lubrication; lubricate the Clutch and

gear train with the recommended grease.

NOTICE

Do not apply too much or too little grease.

Tool outputs high

torque.

Is the shut-o brake functioning properly? Refer to problem No. 5 to check shut-o brake malfunctions.

Is the Clutch properly lubricated?

No lubrication on the Clutch components; lubricate the clutch with

recommended grease.

Is there wear on the face of Cam Guide

where it contacts the Spindle Assembly?

Cam Guide is worn; replace the Cam Guide.

Clutch Spring is damaged; replace the Clutch Spring.

Tool outputs low

torque.

Is the Clutch Housing Assembly joint

tight?

Loose joint between the Gear Case and Clutch Assembly; tighten the joint

with a torque wrench to the specied torque.

Cam is worn; replace the Cam.

Clutch Spring is damaged; replace the Clutch Spring.

Cam Guide is damaged; replace the Cam Guide.

Wiring Diagrams

Micro Switch

Shuto/Brake

Switch

Green

Blue

Green

or Blue

White

Red

Coil

115V AC

Motor

Micro Switch / Start Switch

Black

Yellow

Resistance

Gray

Yellow

Brown

Orange

Control

Base Assembly

The Reverse

Side

Reverse Switch

Ground to

Clutch Housing

(Dwg. TPD1047-2)

(Dwg. TPD1014-3)

Ingersoll-Rand ES 115V AC Series Maintenance Information

Ingersoll-Rand ES 115V AC Series Maintenance Information

Ingersoll-Rand ES 115V AC Series Maintenance Information

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